Densified foam core (dfc) board for use as a backing surface

ABSTRACT

A waterproof board for use as a backing surface comprising a top face, a bottom face, a plurality of sides, a core layer having a thickness of about 5 millimeters, and a sound layer having a thickness of about 2 millimeters. The sound layer is generally interconnected to the core layer. The core layer may comprises at least two faces, either of which may comprise a textured surface. The textured surface may comprise either a substantially smooth finish or a substantially abrasive finish. The core layer comprises a densified foam material having a density of 490 kg/m 3  to about 520 kg/m 3 , and a specific material composition, both of which enhance waterproofing and attain an optimal balance between rigidity and severability.

CLAIM OF PRIORITY

The present invention claims priority under 35 U.S.C. Section 119(e) to a currently pending U.S. provisional patent application having Ser. No. 62/409,654 and a filing date of Oct. 18, 2016, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention is directed to a rigid panel or board made from synthetic materials and which is suitable for use as a backing support against which a variety of coverings may be installed. The inventive board comprises at least a core layer made from a densified foam material having a predetermined structural integrity with sufficient rigidity suitable for installation and the attachment of a variety of coverings thereon. In addition, the densified foam material of the core layer has a predetermined structural integrity to allow a user to make a score line on the board and sever it into smaller pieces.

Description of the Related Art

During the construction of a home, building or other structure, there will almost always be an unfinished wall surface such as concrete block, a wood structure or the like, which needs to be finished to offer a more appealing and/or polished appearance. This is also true of most unfinished floor surfaces. Traditionally, various cement based products, such as mortar or “thin-set” have been used to treat such unfinished surfaces and aid in making them more even or level, and often times, tiles of marble, stone, ceramic, and the like are also applied as part of the process. Other products used to treat unfinished surfaces, such as uneven floors or slabs, include plywood underlayment products that may come in sheets or planks having a thickness of about 6 millimeters. Because plywood underlayment products are not waterproof, their application is generally limited to horizontal surfaces. Additionally, the installation of plywood underlayment products and/or cement based products is often tedious, labor intensive and time consuming. For example, plywood sheets and cement based mixtures are often heavy and cumbersome, plus cement based mixtures and related products need time to cure or harden.

As a result, it has become relatively common to use pre-formed boards made of cementitious materials and attach them to such surfaces in order to provide a backing support that is substantially level, and against which a covering or finish product may be installed. Some known “cement boards” are useful in those areas of a building structure where water and moisture occur, such as in kitchens and bathrooms, and are commonly used as wall surfaces in bathrooms due to their ability to withstand relatively high levels of humidity and to serve as a backing support against which tiles of marble, stone and the like can be applied. In contrast, however, other pre-formed boards known as “drywall,” which are made of gypsum plaster and also used on interior walls of a building structure, do not typically serve as a backing support for tiles, and also, are very susceptible to moisture and/or humidity and therefore, are not suitable for wet environments such as in a bathroom, near a shower, etc.

There are several disadvantages associated with both known drywall and cement boards, which include a relatively high cost of the material, the heavy weight of the material and the resulting difficulty associated with shipment, delivery and installation, as well as attendant higher labor costs. Another disadvantage associated with such boards is that there is often a considerable amount of waste generated. Additionally, cement boards tend to be thicker than other types of boards used as wall surfaces, and add difficulty to the installation process as well as spatial constraints, which can be problematic particularly in small areas or tight spaces.

As such, it would be beneficial if a new backing support product could be made out of a material that is relatively thin, relatively lightweight, not cementitious, and which also offers waterproofing properties. If any such improved backing support were developed, it should also be sufficiently rigid so as to be capable of being secured to a surface without causing any damage to the backing support itself, while also capable of supporting a covering without being damaged. Further, if any such improved backing support were developed, it should also have an ability to be readily modified or cut into any desired sizes or shape upon installation. Ideally, if any such improved backing support were developed, it would be capable of offering certain sound proofing or sound attenuation properties, which is desirable for use in multi-story developments such as condominiums, hotels, etc.

SUMMARY OF THE INVENTION

The present invention is intended to present a solution to these and other needs which remain in this field of art, and as such, is directed to a panel or board made of synthetic materials, and having a structural integrity and sufficient rigidity to permit installation on a surface and to support a variety of coverings thereon. The inventive board overcomes some of the drawbacks of existing plywood underlayment and cement based products as the inventive board is waterproof and can therefore be used on both horizontal and vertical surfaces, and also in different areas of a building such as bathrooms, other areas likely to be exposed to moisture or humidity, as well as with many desired types of flooring surface(s). The coverings, which may be installed in overlying supported relation to the inventive panel or board, may include tiles made of stone, marble, granite, and the like but also others such as, but not limited to, laminate flooring, vinyl composite tiles (VCT), wood planks and other flooring products. In at least one embodiment of the present invention, however, the panel or board can be formed to include a dye or colorant(s) in order to coordinate with a particular color scheme for the surrounding area, and in other embodiments can itself be directly painted, so that in some instances, the present invention can be used to finish a building floor, wall or other surface, and its use with other coverings is not necessary.

The panel or board of the present invention, which can be formed to offer various sizes and dimensions, comprises a core layer having a first or top surface, an oppositely disposed second or bottom surface, and a substantially uniform thickness that in some embodiments is within a range of generally about 4 millimeters to about 6 millimeters, and ideally about 5 millimeters. Also, a textured surface is formed on at least a portion of either the first top surface or the second bottom surface. The textured surface comprises, in at least one embodiment, an abrasive finish formed at least partially, if not entirely, on either the first or second surface, to facilitate use with an adhesive or other material such as “thin-set” or mortar. In some embodiments, both surfaces may include a textured surface, such as but not limited to, a substantially abrasive finish on one of these surfaces and a substantially smooth finish on the other, which may be desirable in other instances.

In addition, the panel or board of the present invention has a core layer comprising a densified foam material having an optimal density that achieves balance between rigidity and severability. More specifically, the densified foam material has a predetermined structural integrity so as to be sufficiently rigid to permit installation onto a selected surface without causing damage to the panel or board, and also, adequate structural support to one or more coverings thereon, some of which may be heavy. At the same time, the predetermined structural integrity of the densified foam material is sufficiently severable such that a user can cut or “score” a line on the panel or board with a box-cutter, knife or other cutting tool, and subsequently “snap” the panel or board into smaller pieces. As such, the densified foam material will have a optimal density ranging from generally about 450 kg/m³ to about 550 kg/m³, although in one or more preferred embodiments, this will be generally about 500 kg/m³. Additionally, the panel or board of the present invention can be extruded from a foamed high density polyvinyl (PVC) composition comprising in at least one embodiment generally equal amounts of a polyvinyl chloride (PVC) material and calcium powder, as well as stabilizing agents and foaming agents, such as but not limited to a composition of generally about 47% of PVC, and generally about 47% of calcium powder, a stabilizer agent of generally about 3% and a foaming agent of generally about 3%. Additionally, the densified foam material composition and density thereof contribute to the waterproofing properties of the invention, making it ideal for use in moist environments such as kitchens, bathrooms, and showers. It should be noted, however, that in other embodiments, the core layer of the inventive panel or board, including the densified foam material may also comprise other materials and/or formulations.

As one example, the panel or board of the present invention may also comprise in some embodiments a sound layer formed from a sound insulating material that can attenuate sound transmission, which is desirable in some environments where sound reduction is important, such as in multi-story developments. The sound layer may be connected to the core layer and may comprise ethyl vinyl acetate or other sound insulating materials including, but not limited to, cork, rubber, or foam. The thickness of the sound layer may range from about 1 millimeter to about 4 millimeters depending on the desired level of sound attenuation. Additionally, the sound layer may comprise a moisture layer in the form of a plastic film or foil.

These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

FIG. 1 is a perspective view of one embodiment of a board according to the present invention comprising a core layer.

FIG. 2 is a perspective view of a board according to the present invention in another embodiment comprising a core layer and a sound layer.

FIG. 3A is a perspective exploded view of one embodiment of a board according to the present invention comprising a core layer and a sound layer.

FIG. 3B is a perspective exploded view of one embodiment of a board according to the present invention comprising a core layer, and a moisture layer.

FIG. 4 is a perspective view of one embodiment of a board according to the present invention comprising a core layer having a textured surface that is substantially smooth.

FIG. 5 is a perspective view of one embodiment of a board according to the present invention comprising a core layer having a textured surface that is substantially abrasive.

FIG. 6 is a perspective view of another embodiment of a board according to the present invention comprising a core layer having a textured surface that is substantially smooth.

FIG. 7 is a perspective view of another embodiment of a board according to the present invention comprising a core layer having a textured surface that is substantially abrasive.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is directed towards a panel or board, generally indicated as 10, that may be used as backing support for a variety of different applications. While the present invention is referred to herein primarily as a board or panel, it may also comprise a sheet or other similar structure, and consequently, this terminology should not be deemed a limiting factor.

As will be explained in greater detail below, the board 10 of the present invention is intended for installation on an unfinished floor, wall, soffit, ceiling, or other similar surface. By way of example, the board 10 may be secured to an unfinished wall such as a masonry wall or a concrete wall, or against an unfinished floor such as a concrete slab or floor. In most instances, the board 10 will typically be nailed, screwed or drilled into place, but may also be secured by other methods. Also, the board 10 of the present invention is well suited to level an otherwise uneven surface, but it may also be used in a variety of other applications. As another example, the board 10, itself, may be used to form a wall, ceiling, soffit, or other similar partition or divider, and to support a covering or finish. In other words, the board 10 may be disposed against or connected to a support structure such as, but not limited to, a frame or a mount.

After the inventive board 10 is installed in a desired location, a variety of coverings or finishing products may be installed, applied, or otherwise adhered to the board 10. These covering or finish products generally require a flat surface for installation and may include various types of tiles such as, but not limited to, marble, stone, travertine, granite, mosaics, ceramic, porcelain and the like, some of which may be quite heavy. Other coverings can also be used with the inventive board 10, such as, but not limited to, laminate flooring, vinyl composite tiles (VCT), wood planks and other flooring products. Moreover, other coverings or finish products which may also require a flat surface for installation are also within the scope of the present invention.

With reference now to FIG. 1, the panel or board 10 of the present invention comprises at least a core layer, generally represented as 20. As shown, the core layer 20 comprises a first face 22 that defines a top surface 12 of the board 10 and a second face 24 that is oppositely disposed so as to define a bottom surface 14 of the panel or board 10. The core layer 20 will preferably have a uniform thickness between its top surface 12 and bottom surface 14 and be in a range of generally about 4 millimeters to 6 millimeters, although in a preferred embodiment, this thickness will be generally 5 millimeters. Additionally, at least one of these faces, such as 22, 24 or such as surfaces 12, 14 will include a texture formed on at least a portion thereof. In most embodiments, however, the board 10 will have a textured surface formed at least substantially across one of these faces or surfaces. Also in most embodiments, a textured surface can be formed on both of these faces or surfaces. For example, and with reference to FIGS. 4 through 7, the first face 22 and the second face 24 may respectively comprise a first textured surface 26 and second textured surface 28. The texture surface may comprise a smooth finish, although in at least one embodiment, the textured surface comprises an abrasive finish. However, the present invention contemplates a board 10 having both a first face 22 defined by top surface 12 with a first textured surface 26 that may be smooth, and a second face 24 defined by bottom surface 14 having a second textured surface 28 that offers a partially or substantially abrasive finish.

As represented in the illustrative embodiments of FIGS. 1-7, the board 10 may comprise a substantially rectangular shape, having a pair of elongated sides or edges 16 and a pair of shorter sides or edges 16′. Other configurations for the panel or board 10 are possible and within the spirit of the present invention, such as but not limited to, substantially square, trapezoid, circular or other shapes. Also, and while the board 10 may be formed to have other dimensions, in the embodiment having a rectangular shape, the board 10 may be manufactured to have dimensions that generally correspond to the spacing commonly found between drywall studs. By way of example only, the dimensions of the board 10 may be approximately thirty six (36″) inches wide by approximately sixty (60″) inches long.

The core layer 20 of the inventive panel or board 10 additionally comprises a densified foam material having a predetermined structural integrity. This predetermined structural integrity is the result of the specific material composition and density range of the densified foam material, and allows for an optimal balance between rigidity and severability that makes the board 10 ideal for use as a backing support. For example, the inventive board 10 is sufficiently rigid so that the board 10 can be installed and secured to an unfinished wall or floor surface, whether by nails, screws or other fastening mechanism without damaging the board, such as by the head of the screw or nail penetrating the surface of the board 10. In addition, the board 10 is sufficiently rigid so as to provide adequate support to one or more tiles, or other coverings disposed thereon. Moreover, the inventive board 10 should at the same time be sufficiently severable, so as to allow a user to expeditiously cut, trim or otherwise form the inventive board 10 into a desired shape by “scoring” a line(s) on the board 10 with a box-cutter, knife or other cutting tool, and subsequently break or snap off a piece of the board 10 along the scoring line. For example, and due to the composition and thickness of the board 10 in some embodiments, a user may use a box-cutter, knife, or other similar instrument to “score” a line(s) on the inventive board 10 at a depth of approximately 2 millimeters to approximately to 3 millimeters below the top surface 12 of the board 10, and thereafter, readily snap or break off the board 10 into smaller pieces along the scoring line.

Accordingly, the core layer 20 comprises a densified foam material that is preferably a foamed, high density, polyvinyl chloride (PVC) material. While the specific composition of the densified foam material may vary, it generally comprises a combination of a synthetic plastic polymer such as polyvinyl chloride (PVC), calcium powder, and foaming agent. In at least one embodiment, the material composition of the densified foam material comprises polyvinyl chloride (PVC) and calcium powder in generally equal amounts. For example, the densified foam material may comprise polyvinyl chloride (PVC) in an amount of between generally between about 45% to about 48%, and calcium powder in an amount also generally between 45% to about 48%, as well as stabilizing agent(s) in an amount of approximately 3% and foaming agent(s) in an amount of approximately 3%. The foaming agent may be a mixture of several materials that enhance stability. Additionally, the density of the core layer 20 and its densified foam material may range from about 450 kg/m³ to about 550 kg/m³, with very favorable results attained with a density of 500 kg/m³.

A feature of the board 10 of the present invention is that either of the faces 22 or 24 of the core layer 20 may be modified or roughened to facilitate adhesion. As is represented in FIGS. 4 and 7, the board 10 of the present invention, and more specifically the core layer 20, is initially manufactured so that all of its faces, such as 22 and/or 24, comprise a substantially smooth finish. As such, either or both of the first textured surface 26 and/or second textured surface 27 may comprise a substantially smooth finish, generally indicated as 27. As is represented in FIGS. 5 and 8, either or both of the first face 22 or second face 24 of the core layer, may be modified or roughened to achieve a substantially abrasive finish, generally represented as 29. As such, at least a portion of the core layer 20 may be passed through a light sander to roughen it thereby creating a substantially abrasive finish 29 on either or both of its faces 22 or 24. With a substantially abraded finish 29, an adhesive such as thin-set, mortar, or another compound, can better adhere to either face 22 or 24 of the core layer 20. Providing a board 10 comprising a core layer 20 with a substantially abraded finish 29 is particularly useful if an adhesive or other compound is required to install the exposed surface. Conversely, a substantially abrasive finish 29 may not always be needed, such as in a face 22 of 24 of the core layer 20, against which may not be installed an exposed surface. Hence, a substantially smooth finish 27 is acceptable on areas that may be intentionally left exposed, such as for example inner portions of walls. Further, if the board 10 comprises is a sound layer 30, then the face 22 or 24 of the core layer 20, that is connected either face 32 or 34 of the sound layer, may also comprise a substantially smooth finish 27 in lieu of a substantially abraded finish 29.

As previously mentioned, yet additional features of the present invention include providing a board 10 with sound attenuation properties. Therefore, and as shown in FIGS. 2-3A, the inventive board 10 may also comprise a sound layer, generally represented as 30. The sound layer 30 may be structured to lessen sound transmissions in environments where sound attenuation is important. These environments may include, but are not limited to, multi-story developments such as condominiums, apartments, hotels, retail spaces, office towers, hospitals, and several others. The sound layer 30 may comprise ethyl vinyl acetate which is a material that has sound attenuation properties. Other sound attenuating materials, however, are also within the scope of the present invention. For example, the sound layer 30 may comprise other materials such as, but not limited to, cork, rubber, or foam. The overall thickness of the sound layer 20 may vary, but generally ranges from about 1 millimeter to about 4 millimeters depending on the desired level of sound attenuation and on spatial constrains. This range may also be about 1.5 millimeters to about 3 millimeters as a sound layer 30 having a thickness of about 2 millimeters may be optimal. Additionally, as represented in FIGS. 2-3B, the sound layer 30 may also comprise a plurality of edges 36. The plurality of edges 36 of the sound layer 30 may substantially overlap or be substantially coincident with the plurality of sides 16 of the board 10. Alternatively, as is represented in FIG. 2, the sound layer 30 may be disposed so that the edge(s) 36 are in a substantially offset relation to the side(s) 16 of the board. That is, a substantially offset relation, between the edge(s) 36 of the sound layer 30 and the side(s) of the board 10, may be desirable so as to provide an area of the board 10 where a user may be able to cut the board 10 without having to cut or otherwise damage any portion of the sound layer 30.

Moreover, as represented in FIG. 3B, the board 10 of the present invention may also comprise a moisture layer, indicated as 40. The moisture layer 40 generally comprises an elastic material such as, but not limited to, a plastic film or a foil, and serves as a moisture barrier between the sound layer 30 and the core layer 20. A moisture layer 40 may be appropriate when the inventive board 10 is used as a leveling surface against a slab that is substantially disposed at grade level. There may be excess moisture in a slab, especially due to saturation of the underlying soil or substrate. In such instances, a moisture layer 40 may be desirable to prevent damage to the covering or finish. As is shown in FIG. 3B, the moisture layer 40 is generally connected to the core layer 20. When the board 10 is installed, the moisture layer 40 should face the underlying surface such as the slab on grade so as to serve as a moisture barrier.

In at least one embodiment of the present invention, the panel or board can be formed to include a dye or colorant(s) in order to coordinate with a particular color scheme for the surrounding area. In other embodiments, however, the inventive board can itself be directly painted, so that in some instances, the present invention can be used to finish a building floor, wall or other surface, and its use with other coverings is not necessary.

Since many modifications, variations and changes in detail can be made to the described preferred embodiment of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.

Now that the invention has been described, 

What is claimed is:
 1. A board intended for use as a backing support comprising: a core layer having a first face and an oppositely disposed second face, said core layer formed of a densified foam material having a predetermined structural integrity; said predetermined structural integrity of said core layer being sufficiently rigid to support one or more coverings thereon, said predetermined structural integrity of said core layer also being sufficiently severable so that a user may score and break said board into smaller pieces, and a textured surface formed on at least a portion of either said first face or said second face.
 2. The board as recited in claim 1 wherein said predetermined structural integrity is also sufficiently rigid to permit installation of said board without damage.
 3. The board as recited in claim 1 wherein said core layer comprises waterproofing properties.
 4. The board as recited in claim 1 wherein said densified foam material is waterproof and comprises polyvinyl chloride and calcium powder in generally equal amounts of between about 45% to 48% each, and generally about 3% to 6% of a stabilizing agent and a foaming agent.
 5. The board as recited in claim 1 wherein said densified foam material comprises a density of about 450 kg/m³ to about 550 kg/m³.
 6. The board as recited in claim 5 wherein said densified foam material comprises a density of about 490 kg/m³ to about 510 kg/m³.
 7. The board as recited in claim 1 wherein said core layer comprises a thickness of generally about 4 millimeters to about 6 millimeters.
 8. The board as recited in claim 1 wherein said core layer comprises a thickness of about 5 millimeters.
 9. The board as recited in claim 1 wherein said textured surface comprises a substantially abrasive finish.
 10. The board as recited in claim 9 wherein said textured surface is formed on substantially all of said first face.
 11. The board as recited in claim 10 wherein said second face includes a textured surface.
 12. The board as recited in claim 11 wherein said textured surface on said second face comprises a substantially smooth finish.
 13. The board as recited in claim 1 wherein said textured surface comprises a substantially smooth finish.
 14. A waterproof panel for use as a backing support for coverings comprising: a core layer having a first surface and a second surface, said first surface including a substantially abrasive texture, said core layer comprising a densified foam material having a density of between generally about 490 kg/m³ to about 520 kg/m³ to provide a structural integrity having sufficient rigidity to support one or more coverings and for installation of the panel without damage, and a sound layer connected to said core layer and structured to reduce sound.
 15. The panel as recited in claim 14 wherein said densified foam material is also severable upon being scored by a user and flexed along a score line created by the user.
 16. The panel as recited in claim 14 wherein said sound layer comprises ethyl vinyl acetate.
 17. The panel as recited in claim 14 wherein said sound layer comprises at least one material selected from the group consisting of cork, rubber, or foam.
 18. The panel as recited in claim 14 further comprising a moisture layer disposed in interconnecting relation between said core layer and said sound layer.
 19. The panel as recited in claim 14 wherein said sound layer comprises a thickness of about 1 millimeter to about 4 millimeters.
 20. A waterproof board having at least one side used as backing support for a plurality of coverings, said board comprising: a core layer having a first face and a second face, each having a textured surface formed at least partially thereon; said core layer having a thickness of generally about 5 millimeters between said first face and said second face, and comprising a densified foam material having a density of between generally about 490 kg/m³ to about 520 kg/m³; said core layer also having a predetermined structural integrity so as to be sufficiently rigid to support the coverings and to permit attachment of said board to a surface without damage; said predetermined structural integrity of said core layer also being sufficiently severable so that a user may score and sever a piece of said board; and a sound layer comprising a thickness of generally about 2 millimeters and structured to reduce sound. 